Method for producing cereal bread

ABSTRACT

According to this method, the seeds previously cleaned and still having their germs are steeped in an aqueous medium (water or activated water with or without nutriments) in an amount of at least 0.6 liter per 1 kg of seeds until the acidity of the aqueous medium reaches 2 to 12 degrees and until the swelling rate of the seeds is characterized by their capacity, under compression, to flatten while loosing the undamaged germ. The aqueous medium where the seeds are steeped is drained and the seeds are ground in order to remove the liquid fraction which is not related to the humid seed mass thus obtained. The dough is kneaded until the target consistency is reached while adding the ingredients indicated in the recipe. The dough is then cut, allowed to rest for 15 to 50 minutes at 35-99° C. while maintaining humidity balance conditions in the dough-atmosphere system, and eventually baked is undertaken at 200 to 300° C., provided that during the first 15 to 200 seconds the dough is in a steam-saturated medium. The seeds can further be additionally washed before their grinding while the liquid fraction removed during the grinding process is used as an ingredient for the dough.

The present invention relates to the food industry and may be used forproduction of bread and other bakery product from grain.

BACKGROUND OF THE INVENTION

There is a known method of bread production, which involves steeping thepreviously cleaned seeds in water under the temperature of 8-40centigrade in the duration of 5 to 24 hours, grinding the previouslycleaned seeds to obtain the seed paste, kneading the dough by the seedpaste with prescribed by the recipe ingredients, separating the seeddough into forms, allowing to rest and baking (Author Certificate USSRNumber 1214054, MPK A 21 D 13/02, 1986—analogue).

There is a known method of bread production, which involves steeping thepreviously cleaned seeds in water, grinding of the seeds, kneading thedough by mixing the seed paste with water and yeast, cutting of seeddough into forms, allowing to rest and baking. The process of the seeddough mixing up is undertaken via mechanical impact on the seed pastewith the frequency of 2 to 15 G in the period of time required for theseed paste maturation; the seeds are steeped in the period of time of 6to 24 hours, yeast is used in the quantity of 2.1 to 5.0 per cent of thegrain weight (Patent USSR Number 1837778, MPK A21 D 13/02,1993—analogue).

The most similar by the technical characteristics method of productionto the described one is the method of the bread production whichinvolves steeping the previously cleaned seeds having their germ inwater, grinding the seeds until seed paste with consistency of no morethan 500 mkm is reached; kneading the dough by mixing up the seed pastewith water and yeast, cutting into forms, allowing to rest and baking.The yeast used for the seed dough is the processed non-activated yeastin the amount of 2.1-5.0% of the seed dough weight; and water is used inthe amount as to ensure the seed dough humidity of 48-52 percent (PatentUSSR Number 1837779, MPK A 21 D 13/02, 1993—prototype).

All the above captured methods of the bread production result in cerealbread being of low shape and insufficient density, with increasedacidity level, and therefore with low organoleptic characteristics.

SUMMARY OF THE INVENTION

An object of our invention is developing a industrial method forproducing the cereal bread with complex high technical result what iscombining the good organoleptic characteristics (shape, taste and scent,appearance of the crunch, colour, and the elasticity of the breadtexture) with the increased biological value of the end product.

According to the invention, a method for producing cereal breadcomprising the steps of a steeping the previously cleaned seeds havingtheir germs; a grinding the previously cleaned seed having their germ tomake seeds paste; the dough is kneaded until the target consistency isreached mixing up the making seed paste with the adding ingredientindicated in the recipe, cut, allowed to rest and eventually baked.

The method further includes the steps of:

the previously cleaned seeds having their germ are steeped in an aqueousmedium in an amount of at least 0.6 liter per 1 kg of seeds until theacidity of the aqueous medium reaches 2 to 12 degrees and until swellingrate of the seeds is characterized by their capacity, under compression,to flatten while loosing the undamaged germ; and

aqueous medium where the seeds are steeped is drained; and

the seeds are ground in order to remove the liquid fraction which is notrelated to the humid seed paste thus obtained; and

the allowing to cut dough to rest for 15 to 30 minutes at 35-99° C.while maintaining humidity balance conditions in the dough-atmospheresystem; and

eventually baking is undertaken at 200 to 300° C., provided that duringthe first 15 to 200 seconds the dough is in a steam-saturated medium.

In the process of the seeds steeping in an aqueous medium is used water,as well as active water with nutriments or without them. After theaqueous medium has been drained the seeds can be additionally rinsedbefore grinding. For the higher biological value of the bread some ofthe removed and stored liquid fraction from the grinding process can beused as an ingredient in seed dough kneading.

DETAILED DESCRIPTION

For the purposes of implementation of the herein-described method of thecereal bread production both wheat and rye can be used. The hereindescribed method is implemented in the following consequence: The seedsare cleaned from all the alien substances and mineral dust, peeled usingthe traditional method of the outer layer seed peeling and consequentmechanical impact (either using brushing or peeling machine of the typeMO-500), and then rinsed again. It is important that the chosen methodof the seed peeling ensures that the seed germ is preserved, and alsoprevents formation of crackles in the seed. The previously cleaned seedshaving their germ are steeped in aqueous medium in an amount of at last0.6 liters per 1 kg of seeds. In an aqueous medium is used pure oractive water. Using the active water is beneficial, as it insures thebetter quality of the seed dough, and therefore increases the cerealbread porosity. To increase biological value of the seeds, variousnutriments (e.g. biological food value addition, salt, etc.) can beadded to the aqueous medium. The steeping is undertaken under thetemperature of 25 to 45 centigrade in the duration of time until theacidity of the aqueous medium reaches 2 to 12 degrees and until swellingrate of the seeds is characterized by their capacity, under compression,to flatten while loosing the undamaged germ. Under the above conditionsthe first stage of the seed germ growing/germination/starts. During thisstage the gluten, which forms part of the seed germ, is neutralised.That eliminates its negative impact on the seed dough (i.e. it makes itwatery and dim), and the final product less elastic and less porous.Secondly the ability of the germ to be released easily guarantees thatit will not be damaged in grinding; that leads to the balance of theamino acids and proteins in the bread, and also concentration ofvitamins B group, E, PP and other minerals, including calcium. Theaqueous medium is drained. That removes the acids, which have negativeimpact on the taste and the scent of the cereal bread, but also on itsporosity. That affect can be reinforced by additional rinsing. For thatpurposes the swollen seeds are put on the sieve and are rinsed by astream of clean water. The swollen seeds are ground. The liquid fractionevolved is removed. That is implemented by using the dispergator typeD150. The seed paste consists of the seed layers and the undamaged seedgerm. The removal of the liquid fraction ensures even share of the seedgerms among the seed paste, which has a positive impact on the breadporosity and in high organoleptic characteristics combined with goodbiological value. The removed liquid fraction is to be collected inclean jars and to be used as an ingredient in the seed dough mixing upprocess, as it is rich in organic. The seed dough in mixed up, usingkneading equipment type A2-XTM. The consistency of the ready seed doughdepends on the type of seeds used (e.g. wheat, rye, or the mixture ofthe above). Ingredients (yeast, food value additions) prescribed by therecipe are added. In the mixing of the seed dough pure water can beused, as well as liquid fraction removed during the grinding process.The seed dough should be elastic and should pulsate and restore theoriginal shape when de-formed. Adding the liquid fraction removed fromthe grinding process has an additional technological benefit. Theprotein from the germ, dissolved in the water, ensures better structuralconnection and stickiness in the process of seed dough mixing. That inturn ensures high level of porosity—a prerequisite for high organolepticcharacteristics. The seed dough is cut on the trays and allowed to rest.The resting process is undertaken in the duration of 15 to 50 minutesunder the temperature of 35 to 99 centigrade and the humidity balanceconditions in the dough-atmosphere system, for example using bakingequipment type G4PE, equipped with the air humidifier. The humiditybalance condition in the dough-atmosphere system results in constanthumidity level within the cereal bread. The end of the resting processis judged subjectively based on visual characteristics (e.g. shape) ofthe seed dough. However, on batch automated lines—judging on time whichis defined by experimentation, depending on type and quality of the rawseeds. The resting process under maintained humidity balance conditionsin the dough-atmosphere system is vital for achieving high quality ofthe final product. The humidity balance conditions prevent seed doughfrom being covered in dry scab. The dry scab has a negative impact inthe baking stage as it limits the evaporation of the water from the seeddough, and therefore decreases the porosity and elasticity of the finalcereal bread product. Baking is undertaken under the temperature of 200to 320 centigrade in the bakery ovens, type KAP-400, which are equippedwith water sprayers The first 15 to 200 seconds the process isundertaken in a steam-saturated medium. Specific progammes for thebaking are set subject to the product weight and dough forms, as well astype and quality of the seeds.

The importance of the steam-saturated environment is two-fold. On onehand it fosters three parallel processes of—‘post fermenting stage oftie dough’, ‘correcting errors of forming’, and finally ‘intensiveheating of the dough’. On the other hand it leads to the appearing ofthe shiny crunch—a specific criteria of the otganoleptic characteristicsof the cereal bread according to the herein-described invention.

EXAMPLE 1

In this example the Kazakh wheat was used. This type of wheat ischaracterised by high elasticity and the level of gluten of 25 percent(the index of internal deformation of gluten equals to 35 percent). Theseeds are cleaned from all the foreign substances and mineral dust.Thoroughly cleaned and rinsed seeds having their germ are steeped inaqueous medium in proportion of 0.9 liters of water to 1 kg of thegrain. The start up temperature of the water was 25 centigrade, and theair temperature was 15 centigrade. The steeping was undertaken until theacidity level of the water reached 3 degrees and swelling rate of theseeds which was characterized by their capacity, under compression, toflatten while loosing the undamaged germ. The aqueous medium was drainedby means of filtering on a sieve. The steeped seeds were rinsed usingthe water with the temperature of 15 centigrade. The moisture seeds wereground using the equipment type D150 until a moisture seed paste wasreached. The liquid fraction, which evaporated during the grindingprocess, was removed and stored. As the result of the grinding processthin seed paste was made, which consisted of preserved seed germ, partof the outer layer of the grain, as well as range of amino acids,vitamins, natural sugar, etc. In order to mix up the seed dough thefollowing components were added to the seed paste: the removed andstored liquid fraction from the grinding process, yeast (in proportionof 40 g per 1 kg of seeds) and salt (in proportion of 16 g per 1 kg ofseeds). The seed dough was kneaded using the equipment type A2-XTM untilhomogeneous seed dough was reached. In order to bake the final productwith the weight of 250 grams the seed dough was cut in baking forms (305grams each) and was allowed to rest. The fermenting process wasundertaken in the duration of 50 minutes under the temperature of 35centigrade and humidity balance condition in the dough-atmospheresystem. The equipment used for fermenting was of type G4PRA.

The baking of the bread was undertaken in the baking oven type KAP-400under the temperature of 310 centigrade while the first 60 seconds werein a steam-saturated medium. The process was controlled visually, untilthe appearance of the dark brown, uneven shiny crust. The ready bakedcereal bread was of high volume, light brown, with crusty sides of therelatively thin size. On the dimension of the sides there were evenlyplaced the brown spots—the traces of the germs. The texture of the breadwas elastic, with specific brown spots of the germs. The porosity of thebread —73%.

EXAMPLE 2

The process was undertaken in Example 1. However, a different sort ofthe wheat was used, which consisted of both Kazakh (65%—gluten level of35 percent) and ordinary wheat (from Tula and Lipeck regions—35%) withlevel of gluten of 21-22 percent. The aqueous medium used for steepingwas active water in proportion of 0.7 liters per 1 kg of seed. The startup temperature of the active water was 30 centigrade and the airtemperature was 25 centigrade. The steeping was undertaken until theacidity level of the aqueous medium reached 7.5 degrees and swellingrate of the seeds was characterized by their capacity, undercompression, to flatten while loosing the undamaged germ.

In order to bake product with the weight of 400 grams the seed dough wascut in forms (470 grams each) and was allowed to rest.

The fermenting was undertaken in the duration of 15 minutes under thetemperature of 90 centigrade while maintaining the humidity balance inthe dough-atmosphere system. The baking of the bread was undertakenunder the temperature of 210 centigrade, in the first 100 seconds thedough was in the steam-saturated medium. The process was controlledvisually, until the appearance of the dark brown, uneven, shiny crust.The cereal bread was of volume, light brown, with crusty sides of therelatively thin size. On the dimension of the sides there were evenlyplaced the brown spots—the traces of the germs. The texture was elastic,with specific brown spots of the germs. The porosity of the bread—67%

EXAMPLE 3

The process was undertaken as in Example 2 but for the following:

The aqueous medium used for the steeping of the seeds was pure water inproportion of 0.6 liters per 1 kg of the seeds with the start uptemperature of 45 centigrade. The process was continued until theacidity level of 9 degrees and swelling rate of the seeds wascharacterized by their capacity, under compression, to flatten whileloosing the undamaged germ. For the final product with the weight of 800grams the seed dough was cut in the forms (890 grams each). Thefermenting process was undertaken in the duration of 25 minutes underthe temperature of 60 centigrade. The baking process was undertakenunder temperature of 280 centigrade. In the first 180 seconds the doughwas in a steam-saturated medium. The cereal bread was of high volume,light brown, with crusty sides of the relatively thin size. On thedimension of the sides there were evenly placed the brown spots—thetraces of the germs. The texture was elastic, with specific brown spotsof the germs. The porosity of the bread—74%.

PRACTICAL IMPLEMENTATION

The herein captured invention can be used for practical implementationin the industry for the production of the cereal bread with increasedorganoleptic characteristics. The herein captured method of productiondespite of having no specifically designed fermenting process proceduresstill ensures good porosity of the final grain bread. The final breadhas an elastic texture, with a shiny crust; it is of light brown to darkbrown colour.

What is claimed is:
 1. A method for producing cereal bread comprisingthe steps of steeping cleaned seeds having their germs in an aqueousmedium containing at least 0.6 liter of aqueous medium per kg of seeds,until the swelling of the seeds is characterized by their capacity,under compression, to flatten while releasing undamaged germ; separatingthe seeds from the aqueous medium; thereafter grinding the seeds to forma seed paste and removing any liquid fraction; mixing the seed pastewith additional ingredients including yeast, to form a bread dough;kneading the bread dough; allowing the dough to rest for 15 to 30minutes at 35 to 99° C. while maintaining humidity balance conditions inthe dough atmosphere system; baking the dough at 200° to 320° C. underconditions wherein during the first 15 to 200 seconds the baking is donein a steam-saturated atmosphere, thereby to form the bread.
 2. Themethod according to claim 1, wherein said aqueous medium is water oractivated water with nutriments or without nutriments.
 3. The methodaccording to claim 1, wherein before grinding, the seeds areadditionally washed after draining the aqueous medium where the seedsare steeped.
 4. The method according to claim 1, wherein the liquidfraction removed during the grinding process is used as an ingredientfor the dough.
 5. The method according to claim 2, wherein beforegrinding the seeds are additionally washed after draining the aqueousmedium where the seeds are steeped.
 6. The method according to claim 2,wherein the liquid fraction removed during the grinding process is usedas an ingredient for the dough.
 7. The method according to claim 3,wherein the liquid fraction removed during the grinding process is usedas an ingredient for the dough.
 8. The method according to claim 5,wherein the liquid fraction removed during the grinding process is usedas an ingredient for the dough.
 9. The method according to claim 1,wherein said aqueous medium is water.
 10. The method according to claim3, wherein said aqueous medium is water.
 11. The method according toclaim 7, wherein said aqueous medium is water.
 12. The method accordingto claim 1, wherein said aqueous medium is water with nutriments. 13.The method according to claim 3, wherein said aqueous medium is waterwith nutriments.
 14. The method according to claim 7, wherein saidaqueous medium is water with nutriments.
 15. The method according toclaim 1, wherein said aqueous medium is activated water.
 16. The methodaccording to claim 3, wherein said aqueous medium is activated water.17. The method according to claim 7, wherein said aqueous medium isactivated water.
 18. The method of claim 1, wherein the steeping ofcleaned seeds is at a temperature of 25° C. to 45° C.